Product and process for consumer application of stain and water repellant to fabrics

ABSTRACT

A product and process for imparting stain and water repellancy to fabric, wherein a heat-curable resin which has the property of imparting stain and water repellancy to fabric when applied in proper amount to the fabric and cured, and that can be dispensed as an aerosol, is mixed in suitable proportion with a diluent and placed in an aerosol container along with a suitable propellant. The composition is then sprayed onto the fabric until the fabric is wet. The concentration of the resin in the composition is such that when the fabric is wet with the composition, an appropriate amount of the resin is on the fabric to impart stain and water repellancy to it when the fabric is dried and the resin cured. Curing of the resin can be accomplished by ironing the fabric, or by drying the fabric in a clothes dryer at normal settings. A preferred resin is FS-7520, an aqueous-based concentrated fluoropolymer system, manufactured by Fiber-Shield Industries, Inc. of Yaphank, N.Y., diluted with water to obtain a concentration of 3%-4% solids in the composition used in the invention.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates generally to products and processes for the treatment of fabrics to render them stain and water repellant. In particular, the invention relates to a product and process for consumer application of a stain and water repellant composition to fabric.

[0003] 2. Prior Art

[0004] Fabrics are often treated to impart stain and water repellancy to them. These treatments are frequently conducted on a commercial scale, wherein a suitable water proofing and stain resistant composition is applied to large sheets or rolls of the fabric to be treated. The composition is typically applied by spraying, padding, roller coating or knife coating. In some processes, the fabric is passed through a bath containing the composition, and then passed through a drying oven to dry the fabric.

[0005] The commercial products used for making fabrics stain and water repellant include the systems sold by Fiber-Shield Industries of Yaphank, N.Y., under the names FS-7550 and FS-7520. The FS-7550 product is a concentrated fluoropolymer water system, and is slightly cationic. It is sold as a liquid in five, thirty and fifty-five gallon containers, and can be applied via spraying, padding, roller coating or knife coating. In use, 4-6 parts, by weight, of FS-7550 are diluted with 96-94 parts of water and mixed for at least three minutes. Isopropyl alcohol can be added as a preservative. When sprayed onto fabric, the composition normally dries in 10 minutes to 1 hour, depending upon ambient conditions and the amount of composition applied to the fabric. When allowed to air dry, full cure can take about 72 hours. Alternatively, 2-3% of FS-7550 can be added to the rinse cycle of a washing machine to add the composition to the fabric. The fabric is then dried in a dryer at 160° F., and/or ironed. However, the slightly cationic property of the composition may cause it to attach to the surface of machinery, resulting in gumming up of the machinery.

[0006] The FS-7520 product is an air-cured, mildly cationic concentrated fluoropolymer water system, and is sold as a liquid in five, thirty and fifty-five gallon containers. This product is intended to be applied via spraying, padding or roller coating. In use, 7-10 parts, by weight, of FS-7520 are diluted with 93-90 parts of water and mixed for at least three minutes. Isopropyl alcohol can be added as a preservative. When applied to fabric or carpeting, the composition will be dry to the touch within 10 minutes to 1 hour, depending upon the amount of product sprayed and the ambient conditions. Full cure takes place in approximately 24-48 hours.

[0007] Both the FS-7550 and FS-7520 products are intended for use in the commercial treatment of fabric to impart stain and water repellancy, and are formulated and packaged accordingly.

[0008] Other products have been developed for consumer application to fabric to impart stain and water repellancy to the fabric. These consumer products have limited effectiveness, and some have been withdrawn from the market because of their carcinogenic properties.

[0009] Thus, there is need for a safe and effective consumer product that can be applied via aerosol or pressurized container to impart stain and water repellancy to fabrics.

SUMMARY OF THE INVENTION

[0010] The invention comprises a superior, heat-curable, non-toxic, resin-based aqueous composition that is packaged in an aerosol or pressurized container for consumer application to fabric to impart stain and water repellancy to the fabric.

[0011] The concentration of the effective resin-based component in the composition is such that the consumer simply sprays the composition onto the fabric until the fabric is wet, whereupon the appropriate amount of the effective component will have been applied to the fabric to impart stain and water repellancy to the fabric. The wetted fabric is then ironed or placed in a typical clothes dryer and dried at a normal setting. The heat generated by ironing and/or drying the fabric in a clothes dryer sets or cures the resin-based component, imparting a stain and water repellant property to the fabric that is superior to the results obtained with prior art consumer products and processes.

[0012] Applicant has found that the FS-7520 composition of Fiber-Shield Industries, when suitably modified, makes a superior and preferred composition for consumer application via aerosol or pressurized container. The FS-7520 composition comprises 14-16% solids, and applicant dilutes this with water to 3-4% solids. A suitable commercially available corrosion inhibitor may also be added. The diluted composition is then packaged in an aerosol or pressurized container for consumer use as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The foregoing and other objects and advantages of the invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:

[0014]FIG. 1 is a longitudinal sectional view of an aerosol container for consumer application of the stain and water repellant composition of the invention.

[0015]FIG. 2 is a schematic block diagram of one process for treating fabric in accordance with the invention to impart stain and water repellancy to the fabric.

[0016]FIG. 3 is a schematic block diagram of another process for treating fabric in accordance with the invention to impart stain and water repellancy to the fabric.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] In accordance with the invention, a heat-curable resin which has the property of imparting stain and water repellancy to fabric when applied in proper amount to the fabric and cured, and that can be dispensed as an aerosol, is mixed in suitable proportion with a diluent and placed in an aerosol container. The composition is then sprayed onto the fabric until the fabric is wet. The concentration of the resin in the composition is such that when the fabric is wet with the composition, an appropriate amount of the resin is on the fabric to impart stain and water repellancy to it when the fabric is dried and the resin cured. Curing of the resin can be accomplished by ironing the fabric, or by drying the fabric in a clothes dryer at normal settings.

[0018] A particular resin which has been found suitable for use in the composition of the invention is FS-7520, manufactured by Fiber-Shield Industries, Inc. of Yaphank, N.Y. FS-7520 is an aqueous-based concentrated fluoropolymer system that cures at ambient temperatures. For use in the invention, this product is diluted with water to 3%-4% solids, and, if desired, a suitable commercially available corrosion inhibitor added. The composition is then packaged in a conventional aerosol or pressurized container for use by a consumer to impart stain and water repellancy to fabrics. The consumer simply sprays the composition onto the fabric until the fabric is wet, and the concentration of resin in the composition is such that when the fabric is wet an appropriate amount of the resin will be present on the fabric to impart stain and water repellancy to it when the fabric is dried and the resin cured by application of heat. Curing of the resin can be accomplished by ironing the fabric, or by drying it in a clothes dryer at normal settings.

[0019] Treatment of fabric in accordance with the invention produces results superior to those obtained by prior art products and processes, and is easily achieved.

[0020]FIG. 1 depicts a typical conventional aerosol dispenser 10 which can be used in practicing the invention. The dispenser includes a container 11 with a dip tube 12 and actuator-nozzle 13. A desired quantity of the composition 14 of the invention is placed in the aerosol dispenser by using conventional methods, and a suitable propellant is added to pressurize the contents of the package in order that the resin composition can be sprayed. Further, it is recognized that the product could be sprayed with a finger pump or a trigger sprayer, but this would be tiring for covering large objects. For instance, a raincoat would require eight to ten fluid ounces for coverage.

[0021]FIG. 2 schematically depicts one process for practicing the invention, wherein a heat-curable resin 15 that can be dispensed as an aerosol is diluted with a suitable diluent 16 to obtain a composition 14 having 3% to 4% solids. In a preferred embodiment, the resin preferably comprises FS-7520 manufactured by Fiber-Shield Industries, Inc. of Yaphank, N.Y., and is diluted with water. The composition is packaged according to conventional methods in a conventional aerosol dispenser 10, from which the composition is sprayed onto fabric F until the fabric is wet. The concentration of resin in the composition is such that when the fabric is wet, an appropriate amount of the resin will be present on the fabric to impart stain and water repellancy to it when the fabric is dried and the resin cured. Curing of the resin can be accomplished by ironing the fabric with an iron I.

[0022]FIG. 3 schematically depicts another process for practicing the invention, wherein all the steps shown in FIG. 2 are followed, except that the resin is cured by placing the wetted fabric F in a clothes dryer D to dry the fabric and cure the resin. The fabric may also be ironed and otherwise handled conventionally upon removal from the dryer.

[0023] Although stain and water repellancy can be imparted to fabric by applying the composition of the invention and permitting it to air-dry under ambient conditions, cross linking or polymerization of the resin is achieved more effectively by subjecting the material to heat, e.g., by ironing the treated fabric or drying it in a clothes dryer after the composition has been applied to the fabric.

[0024] While particular embodiments of the invention have been illustrated and described herein, it should be understood that various changes and modifications may be made to the invention without departing from the spirit and intent of the invention as defined by the claims appended hereto. 

What is claimed is:
 1. An aerosol product for treating fabric to impart stain and water repellancy to the fabric, comprising: an aerosol container holding a quantity of a composition containing a resin having the property of imparting stain and water repellancy to fabric when applied to the fabric and cured, said composition being capable of being sprayed from an aerosol container, and having said resin therein in sufficient concentration so that when the fabric is wetted with the composition, an appropriate amount of the resin is present on the fabric to impart stain and water repellancy to the fabric when the resin is cured.
 2. An aerosol product as claimed in claim 1, wherein: said resin comprises a fluoropolymer.
 3. An aerosol product as claimed in claim 2, wherein: said composition is aqueous based and comprises said fluoropolymer resin and water, with said resin comprising 3% to 4% of the composition.
 4. A process for treating fabric to impart stain and water repellancy to the fabric, comprising the steps of: preparing a composition containing a resin having the property of imparting stain and water repellancy to fabric when applied to the fabric and cured, and a diluent that dilutes the concentration of resin in the composition to a level that will result in an appropriate amount of the resin being present on the fabric to impart stain and water repellancy to the fabric when the composition is applied to the fabric in a quantity sufficient to wet the fabric; applying the composition to fabric in a quantity to wet the fabric with the composition; and drying the fabric and curing the resin to impart stain and water repellancy to the fabric.
 5. A process as claimed in claim 4, wherein: the composition is applied to the fabric by spraying it from an aerosol container.
 6. A process as claimed in claim 4, wherein: the resin is cured by heating the wetted fabric.
 7. A process as claimed in claim 6, wherein: heating is accomplished by ironing the fabric.
 8. A process as claimed in claim 6, wherein: heating is accomplished by drying the wetted fabric in a clothes dryer.
 9. A process as claimed in claim 5, wherein: the resin is cured by heating the wetted fabric.
 10. A process as claimed in claim 9, wherein: heating is accomplished by ironing the fabric.
 11. A process as claimed in claim 9, wherein: heating is accomplished by drying the wetted fabric in a clothes dryer. 